SubscribeUnivar Ltd is the UK's largest chemical distributor, and has a long history, dating back to 1848. Today Univar is the world leader in chemical distribution with an extensive network of 166 distribution centres across the United States, Canada, and 14 countries in Europe. 2003 saw sales in Europe alone total $1.6 billion.
Univar Ltd serves the UK from 14 sites comprising over 32,500m2 of warehouse facilities and nearly 300 bulk storage tanks. The company is a dedicated supplier and distributor of chemicals and chemical related services to UK industry. It distributes bulk loads for chemical manufacturers direct to their customers, but also supplies chemicals itself to customers requiring smaller quantities.
Much of these operations involve fork-lift trucks. From the unloading of delivery vehicles, to storage, and to re-loading for delivery, materials handling equipment is vital. Univar Ltd’s UK Purchasing Manager Andrew Goldsworthy explains: “We have a fleet of over 100 trucks across our 14 sites, and safety has always been, of course, a primary consideration throughout our organization. However, the introduction of the DSEAR reg’s 2002 (which implement the ATEX directives within the UK) has been a key consideration in our recent purchases of counterbalance trucks.”
Univar has recently installed 19 counterbalance trucks from two different suppliers across its UK distribution centres. All of the trucks are fitted with explosion protection systems from Pyroban.
“We have a relationship with Pyroban that stretches back 20+ years,” continues Andrew Goldsworthy. “We reviewed our site zoning with respect to DSEAR/ATEX and worked with Pyroban to come up with a solution.”
The result is eight trucks fitted with the Pyroban Gascheka ‘added safety’ system and a further eight with System 5000D for 3G trucks working in Zone 2 areas. A further three trucks are fitted with Pyroban’s Zone 1 system Euromech 2G. These work at the Cadishead solvent tank farm, which includes some Zone 1 areas. The other trucks work at Univar’s numerous outdoor flammable solvent storage facilities.
The Gascheka protected trucks are used for loading and unloading delivery vehicles. Pyroban’s Gascheka provides added safety, for use in areas not formally classified. Previously an engine overspeed shutdown valve and spark arrestor would have been specified, but this only addressed a couple of the ignition sources of the diesel trucks. Now following explosion protection measures identified under the ATEX 137, the "Worker Protection Directive", equipment is shut down on detection of a wide range of flammable gases and vapours, and the operators are required to leave the area before explosive conditions are present.
The New System 5000D equipped trucks are used to handle flammable solvents in those storage areas which are designated Zone 2. System 5000D incorporates two methods of protection: gas detection and protection of ignition sources. A forced gas test ensures system integrity prior to operation and the system provides an audible and visible alarm at 10% of the lower explosive limit, followed by shutdown at 25%.
All arcing, sparking, and hot components are risk assessed and fitted with restricted breathing enclosures to limit the ingress of flammable gas/vapour. A water-cooled exhaust gas cooler limits surface and exhaust temperatures to the specified temperature class. Forks are clad in stainless steel, and the gas sensing head is certified for use with gas groups IIA or IIB and is protected to IP54.
“We like the intelligent nature of System 5000,” explains Andrew Goldsworthy. “The fact that it shuts the truck down in the event of any detected risk increases overall safety as it provides an early warning of a potential problem."
In terms of the modifications required to the truck, it is also more cost-effective than a conventional ‘passive’ system, being less intrusive to the OEM design.
Andrew Goldsworthy continues: “The Euromech 2G systems in use at Cadishead have given significant operational efficiencies due to reduced downtime. We also benefit from the fact that Pyroban has ensured that the OEM technicians who service our fleet are also trained and qualified to maintain the Pyroban systems, which leads to further savings for us.”
Contact:
Zoran Milivojevic,
tel: 01273 466232,
fax: 01273 465313,
e-mail: zoran.milivojevic@pyroban.com
web site: www.pyroban.com